A nondestructive replica technique permitting complete inspection of bore surfaces having an inside diameter from 0.050 inch to 0.500 inch is described. Replicas are thermally formed on the outside surface of plastic tubing inflated in the bore of the sample being studied. This technique provides a new medium for inspection of bores that are too small or otherwise beyond the operating limits of conventional inspection methods.Bore replicas may be prepared by sliding a length of plastic tubing completely through the bore to be studied as shown in Figure 1. Polyvinyl chloride tubing suitable for this replica process is commercially available in sizes from 0.037- to 0.500-inch diameter. A tube size slightly smaller than the bore to be replicated should be used to facilitate insertion of the plastic replica blank into the bore.
